Liquiform channel letter

Abstract

Methods and apparatus for substantially reducing dark spots on a front surface of a channel letter, including: forming a channel letter using a profile with at least one rib, the profile having a top and a bottom; coupling a face plate to the at least one rib; and filling a space between the face plate and the top of the profile with a resin material.

What is claimed is: 
     
         1 . A method for substantially reducing dark spots on a front surface of a channel letter, the method comprising:
 forming a channel letter using a profile with at least one rib, the profile having a top and a bottom;   coupling a face plate to the at least one rib; and   filling a space between the face plate and the top of the profile with a resin material.   
     
     
         2 . The method of  claim 1 , wherein the face plate is coupled to a position below the at least one rib. 
     
     
         3 . The method of  claim 1 , wherein the resin material is formed with gel-like material so that the resin material can be poured into the space. 
     
     
         4 . The method of  claim 3 , further comprising
 performing at least one of drying and hardening steps on the gel-like resin material.   
     
     
         5 . The method of  claim 1 , wherein the resin material is formed with pre-hardened material. 
     
     
         6 . A channel letter formed using a profile including at least one rib, the channel letter comprising:
 a face plate coupled to a first rib of the at least one rib; and   a layer of resin material disposed between the face plate and a top of the profile.   
     
     
         7 . The channel letter of  claim 6 , wherein the face plate is formed with one of plastic or acrylic. 
     
     
         8 . The channel letter of  claim 6 , wherein the face plate is coupled to a position below the first rib. 
     
     
         9 . The channel letter of  claim 6 , wherein the face plate is coupled to a position above the first rib. 
     
     
         10 . The channel letter of  claim 6 , wherein the layer of resin material is formed with gel-like material. 
     
     
         11 . The channel letter of  claim 6 , wherein the layer of resin material is formed with pre-hardened material. 
     
     
         12 . The channel letter of  claim 6 , further comprising
 a bottom plate coupled to a second rib of the at least one rib, the bottom plate configured to accept light emitting diodes used to illuminate the layer of resin material.   
     
     
         13 . The channel letter of  claim 6 , wherein the layer of resin material includes coloring material.